Alternator, Battery, and Starter Connections Check

p3 mm 15.01

    Warning: Batteries generate explosive gas as a by-product of their chemical process. Do not smoke when working around batteries. Put out all flames and remove any source of sparks or intense heat in the vicinity of the battery compartment. Make sure the battery compartment has been completely vented before disconnecting or connecting the battery cables.

    Battery acid is extremely harmful if splashed in the eyes or on the skin. Always wear a face shield and protective clothing when working around batteries.

  1. Disconnect the batteries.
  2. Check the tightness of the alternator bracket fasteners; tighten the fasteners as needed. For torque values, see of the Cascadia™ Workshop Manual.
  3. Check that all electrical connections at the alternator and starter are clean. Clean and tighten all charging system electrical connections, including the connections at the starter B terminal and ground terminal, and where the alternator charging cable terminates.
  4. Inspect the battery cables for wear, and replace them if they are damaged. Clean the cable connector terminals with a wire brush. See of the Cascadia™ Workshop Manual for adjustment, repair, or replacement instructions.
    1. Clean and tighten the battery ground cable, terminal, and clamps.
    2. Inspect the retainer assembly or battery hold-downs, and the battery box. Replace worn or damaged parts. Remove any corrosion with a wire brush, and wash with a weak solution of baking soda and water. Flush with clean water, and dry. Paint the retainer assembly if needed, to prevent rusting.
    3. Check that foreign objects, such as stones, bolts, and nuts, are removed from the battery box.
    4. After cleaning, connect the cables to the batteries and tighten them to the torque specifications listed on the battery, generally 10 to 15 lbf·ft (14 to 20 N·m).
    5. Coat the battery terminals with dielectric grease.
  5. Check the alternator wiring for missing insulation, kinks, and heat damage. Replace or repair as needed.
  6. Check the terminals on the battery shut-off switch and the magnetic switch. Make sure the terminal connections are clean and tight. Coat the terminal connections with dielectric red enamel after cleaning.
Note:
Parent topic: Alternators and Starters
Document Number: 0000110989
Manual Publication Date: 2024-05-15
Topic Publication Date: 2024-11-22